Starter, Assemble (Valeo)
Press bearing bushing (1) flush into starter housing with suitable drift (2) (see illus. I).
After pressing in bearing bushing, secure with two centre-punch marks on outer side of starter housing.
Lightly lubricate armature shaft and spiral spline with lubricating grease (brown) and position freewheel (3) and friction washer (4) onto the armature shaft. Fit snap ring (5) into groove (6) on armature shaft (see illus. II).
Engage thrust washer in retaining ring with remover tool (see illus. III).
Lubricate connecting bar (3) of starter switch lightly with grease (brown). Insert control lever (2) into sleeve (1) on freewheel and insert connecting bar into opening for starter switch. Fit control lever axle.
Place starter switch with spring on tension rod and bolt starter switch to starter (see illus. II).
Lubricate bearing bushing (4) with lubricating grease (brown). Position engaging housing on starter motor and bolt on.
Place seal (1) on carbon brush holder (2) and place these together on retaining pins on starter.
Insert positive carbon brush (3) into carbon brush holder. Insert elbow (4) of stranded connection into guide of gasket. Place cable terminal onto connection of starter switch.
Place positive carbon brush (5) in carbon brush holder. Place cable shoe of negative carbon brush on left retaining pin (6).
Place insulating plates (1) on carbon brushes. Insert spring (2) as shown in illustration and engage in carbon brush holder by pressing firmly on spirals.
Place insulation (3) for housing cover in housing cover and install cover on starter motor.
Fasten positive carbon brush battery lug (4) to starter switch.
Push insulating sleeve (5) onto positive carbon brush connection until it engages.
Check function of starter on test stand or when installed - see operation "Installed Starter, Check".